Gas flow control valve

ABSTRACT

A gas flow control valve comprising coupling means for coupling to a measurement tube, wherein the coupling means are compatible with existing means for coupling valves to the measurement tube, means for directing gas from a well head through the gas flow control valve and out of an exit port, means for finely tuning the flow rate of gas passing through the flow control valve comprising, means for longitudinally translating a valve needle via rotation of a rotating assembly, wherein the valve needle comprises a tapered portion and a shoulder, wherein the tapered portion of the valve needle comprises a truncated cone which increases in diameter in the direction of gas flow, and means for visually indicating the longitudinal position of the gas flow control valve.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is continuation of U.S. patent application Ser. No.13/969,431, filed Aug. 16, 2013, entitled “Gas Flow Control Valve”,which claims the benefit under 35 U.S.C. §119 of U.S. Provisional PatentApplication Ser. No. 61/842,240, filed Jul. 2, 2013, and entitled “GasFlow Control Valve”. The disclosures of the foregoing applications arehereby incorporated by reference in their entirety.

TECHNICAL FIELD

The present technology relates to gas flow control valves and, inparticular, flow control valves configured to finely tune the flow rateof gas extraction from solid waste landfills.

DESCRIPTION OF THE RELATED TECHNOLOGY

To provide some background, once municipal solid waste is disposed of ata landfill, the organic fraction of the waste begins to decompose. Thisdecomposition first proceeds through an aerobic biodegradation processwhere all the available oxygen in the buried waste is consumed. Thedecomposition then proceeds through a strictly anaerobic biodegradationprocess where the principle constituents of landfill gas are formed.Landfill gas consists of approximately 55% methane, 44% carbon dioxideand less than 1% trace gases. The trace gases consist of a wide varietyof volatile organic compounds, which vary depending on the particularlandfill. Noteworthy is the fact that oxygen is toxic to themicroorganisms typically responsible for methane gas generation.

Since landfill gas is constantly being produced as a result of wastedecomposition, landfill gas will move from the buried waste towards theground surface and will result in surface emissions to the atmosphere.The constant generation of landfill gas also results in a flushing orpurging action within the subsurface that results in the removal of air,thus further facilitating the anaerobic biodegradation process.

Surface emissions of landfill gas is not a desirable condition becausethe primary constituents of landfill gas are well known greenhousegases, which are thought to be contributing towards global warming. Inaddition, the trace gases present in landfill gas are believed toparticipate in an atmospheric photochemical reaction that leads to theformation of ozone, a principle constituent of smog.

In addition to surface emissions, landfill gas may also move or migratelaterally in the subsurface away from the buried decomposing waste, andmay accumulate in near-by buildings or other structures. This conditioncreates a potentially dangerous condition due to the methane content oflandfill gas. When methane is present in a concentration ranging fromapproximately 5 to 20 percent by volume it is potentially explosive.Another issue associated with subsurface migration of landfill gas isthat it may also come into contact with groundwater and create thepotential for groundwater contamination due to the presence ofcontaminating trace gases. Thus it is desirable to collect landfill gasto prevent these negative environmental effects. It is also desirable tocollect landfill gas for energy recovery purposes, as the methanecontent of landfill gas can be relatively easily used as a fuel.

Active landfill gas well extraction systems are used to control landfillgas surface emissions, control landfill gas subsurface migration awayfrom the landfill, and often to collect landfill gas for energyrecovery. These systems typically include an array of both vertical andhorizontal landfill gas extraction wells that are in fluid communicationwith a common header piping system. The header piping system is, inturn, fluidly connected to a vacuum source, typically a centrifugalblower or other similar turbo-machine. Following extraction by thesystem, the gas may be incinerated by a flare, may be directly used as afuel, or may be conditioned and then used as a fuel.

The landfill extraction system wells are either drilled or trenched intothe landfill waste column and they consist of both perforated-pipingsections and solid-piping sections. The solid piping section is nearestthe surface of the landfill. The perforated-piping section is the deeperpiping. The point at which the solid piping changes to perforated pipingis a major design consideration for an extraction well, since itsignificantly influences the maximum allowable suction that can beapplied to each well.

Each extraction well is in fluid communication with a header pipingsystem through a wellhead assembly. The wellhead assembly typicallyconsists of a gate valve used for throttling the volumetric flow rate oflandfill gas from the extraction well and a sample collection port. Thewellhead may also include a flow rate measurement device.

An operating goal of the landfill gas well extraction system is toremove gas at the approximate rate of its generation. The rational forthis goal is the consequence of over- or under-extraction rates.Under-extraction rates mean the extraction rate is not high enough toprevent gas from reaching the surface or prevent subsurface migration.This results in air pollution, or a fire hazard. Over-extraction ratesmean the extraction rate is high enough to draw large amounts of airinto the waste column. This may cause a subsurface fire, and will killmany of the microorganisms responsible for the formation of methane,resulting in reduced methane recovery. Consequently, the gas flow ratefrom each individual extraction well, or group of adjacent wells, needsto be carefully monitored and controlled within a narrow operating rangeto prevent over- or under-extraction of landfill gas.

SUMMARY

The systems, methods and devices described herein have innovativeaspects, no single one of which is indispensable or solely responsiblefor their desirable attributes. Without limiting the scope of theclaims, some of the advantageous features will now be summarized.

One aspect of the present invention is the realization that existing gasvalves do not provide the capability for a technician to finely tune theflow rate of gas through the valve in the field. Thus, there exists aneed for a flow control valve which allows for fine tuning of gas flowrate in the field.

One non-limiting embodiment of the present invention includes a gas flowcontrol valve comprising a valve body having a central bore and an exitport, the central bore of the valve body having a valve body centralaxis, the exit port having an exit bore in fluid communication with thecentral bore, the exit port of the valve body having an exit portcentral axis, the exit port central axis of the exit port angled between20 and 85 degrees relative to the valve body central axis; wherein thevalve body has a proximal portion and a distal portion, wherein gasenters the valve body through the proximal portion and exits through theexit port; a threaded member having a proximal portion and a distalportion, the proximal portion of the threaded member affixed to thedistal portion of the valve body, the threaded member having a threadedmember central axis collinear with the valve body central axis, thethreaded member comprising a threaded bore and a sliding bore, thethreaded bore entering from the proximal portion of the threaded memberand the sliding bore entering from the distal portion of the threadedmember, the threaded bore in fluid communication with the sliding bore;a rotating assembly configured to rotate about the valve body centralaxis and to translate along the valve body central axis, the rotatingassembly comprising a handle affixed to a threaded shaft affixed to avalve needle, the handle including a proximal portion and a distalportion, the proximal portion of the handle configured to slide withinthe sliding bore of the threaded member, the proximal portion includingmeasurement indicia configured to indicate the longitudinal position ofthe rotating assembly relative to the threaded member; wherein thethreaded bore of the threaded member is configured to accept thethreaded shaft of the rotating assembly and wherein rotation of therotating assembly relative to the threaded member causes the rotatingassembly to translate relative to the threaded member; wherein the valvebody includes a valve seat configured to receive the valve needle of therotating assembly such that translation of the valve needle relative tothe valve seat alters the flow rate of gas travelling through the gasflow control valve; wherein the exit bore of the exit port is locateddistally from the valve seat of the valve body; wherein the valve needlecomprises a tapered portion; and wherein the sliding bore of thethreaded member is configured to accept the proximal portion of thehandle of the rotating assembly.

According to additional embodiments, the tapered portion of the valveneedle increases in diameter in the direction of gas flow.

According to additional embodiments, the tapered portion of the valveneedle comprises a truncated cone.

According to additional embodiments, the valve needle further comprisesa shoulder protruding outwards from the center of the valve needle,wherein the shoulder is configured to seal with the valve seat when theflow control valve is in a closed position.

According to additional embodiments, the shoulder comprises a proximalface, wherein the proximal face comprises a sealing recess configured toaccept a sealing member configured to seal against the valve seat.

According to additional embodiments, the exit port central axis of theexit port angled between 40 and 50 degrees relative to the valve bodycentral axis.

According to additional embodiments, the threaded bore of the threadedmember and the threaded shaft have a thread pitch configured such thatat least 6 turns of the rotating assembly is required to span anadjustable range of flow rate provided by the gas flow control valve.

According to additional embodiments, the proximal portion of the handlecomprises a sealing recess configured to receive a sealing deviceconfigured to seal the sliding bore of the threaded member.

According to additional embodiments, the measurement indicia of thehandle are configured to be read relative to a distal surface of thethreaded member.

According to additional embodiments, wherein the flow control valve isconfigured to quickly and easily couple to an existing measurement tubevia a union.

Another non-limiting embodiment of the present invention includes a gasflow control valve comprising: coupling means for coupling to ameasurement tube; wherein the coupling means are compatible withexisting means for coupling valves to the measurement tube; means fordirecting gas from a well head through the gas flow control valve andout of an exit port; means for finely tuning the flow rate of gaspassing through the flow control valve comprising: means forlongitudinally translating a valve needle via rotation of a rotatingassembly; wherein the valve needle comprises a tapered portion and ashoulder, wherein the tapered portion of the valve needle comprises atruncated cone which increases in diameter in the direction of gas flow;and means for visually indicating the longitudinal position of the gasflow control valve.

According to additional embodiments, the gas flow control valvecomprises a valve body central axis, wherein the exit port comprises anexit port central axis, and wherein the exit port central axis is angledbetween 20 and 85 degrees relative to the valve body central axis.

According to additional embodiments, the gas flow control valvecomprises a valve body central axis, wherein the exit port comprises anexit port central axis, and wherein the exit port central axis is angledbetween 40 and 50 degrees relative to the valve body central axis.

Another non-limiting embodiment of the present invention includes amethod of manufacturing a flow control valve comprising: affixing thedistal portion of a threaded shaft to a handle; installing the threadedshaft into a threaded bore of a threaded member and a proximal portionof the handle into a sliding bore of the threaded member; affixing avalve needle to the proximal portion of a threaded shaft; sourcing areadily available socket style 45 degree wye fitting comprising a socketformed therein each opening of the wye fitting; machining a bore fromthe distal portion of the wye fitting producing a valve seat in theproximal portion; and inserting the proximal end of the threaded memberinto the distal end of the valve body and affixing the threaded memberto the valve body.

According to additional embodiments, the method further comprisesinserting a distal portion of PVC pipe into the proximal socket of thevalve body and affixing the PVC pipe to the valve body and affixing acoupling means to a proximal portion of the PVC pipe.

The method of claim 14, further comprising inserting a PVC pipe into theexit port socket of the valve body and affixing the PVC pipe to thevalve body and coupling an extraction member to the PVC pipe.

According to additional embodiments, affixing the threaded member to thevalve body comprises inserting at least one retention member into atleast one retention bore passing through the valve body and into thethreaded member.

According to additional embodiments, affixing a valve needle to theproximal portion of a threaded shaft comprises inserting a retentionmember through a retention bore passing through the valve needle andthreaded member.

According to additional embodiments, the method further comprisesmachining sealing recesses into the threaded member, the handle, and thevalve needle configured to accept a sealing member.

According to additional embodiments, the valve needle comprises atapered portion and a shoulder, wherein the tapered portion of the valveneedle comprises a truncated cone which increases in diameter in thedirection of gas flow.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned aspects, as well as other features, aspects, andadvantages of the present technology will now be described in connectionwith various embodiments, with reference to the accompanying drawings.The illustrated embodiments, however, are merely examples and are notintended to be limiting. Like reference numbers and designations in thevarious drawings indicate like elements.

FIG. 1 illustrates a perspective view of one embodiment of a flowcontrol valve coupled to a measurement tube of a well head.

FIG. 2 illustrates a perspective view of the flow control valve of FIG.1 coupled to the measurement tube.

FIG. 3A illustrates a perspective view of gate valve being decoupledfrom a measurement tube.

FIG. 3B illustrates a perspective view of the flow control valve of FIG.1 being coupled to the measurement tube of FIG. 3A.

FIG. 4A illustrates a cross section view of the flow control valve ofFIG. 1 in a closed position and coupled to a measurement tube.

FIG. 4B illustrates a cross section view of the flow control valve ofFIG. 1 in an open position and coupled to a measurement tube.

FIG. 4C illustrates a supplementary view of the cross section of theflow control valve of FIG. 4B.

FIG. 5A illustrates a perspective view of one embodiment of a rotatingassembly.

FIG. 5B illustrates a cross section view of the rotating assembly ofFIG. 5A.

FIG. 6A illustrates a perspective view of one embodiment of a threadedmember.

FIG. 6B illustrates a cross section view of the threaded member of FIG.6A.

FIG. 7 illustrates an exploded view of the union of FIG. 2.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part of the present disclosure. Theillustrative embodiments described in the detailed description,drawings, and claims are not meant to be limiting. Other embodiments maybe utilized, and other changes may be made, without departing from thespirit or scope of the subject matter presented here. It will be readilyunderstood that the aspects of the present disclosure, as generallydescribed herein, and illustrated in the Figures, can be arranged,substituted, combined, and designed in a wide variety of differentconfigurations, all of which are explicitly contemplated and form partof this disclosure. For example, a system or device may be implementedor a method may be practiced using any number of the aspects set forthherein. In addition, such a system or device may be implemented or sucha method may be practiced using other structure, functionality, orstructure and functionality in addition to or other than one or more ofthe aspects set forth herein. Alterations and further modifications ofthe inventive features illustrated herein, and additional applicationsof the principles of the inventions as illustrated herein, which wouldoccur to one skilled in the relevant art and having possession of thisdisclosure, are to be considered within the scope of the invention.

Descriptions of unnecessary parts or elements may be omitted for clarityand conciseness, and like reference numerals refer to like elementsthroughout. In the drawings, the size and thickness of layers andregions may be exaggerated for clarity and convenience.

Features of the present disclosure will become more fully apparent fromthe following description and appended claims, taken in conjunction withthe accompanying drawings. It will be understood these drawings depictonly certain embodiments in accordance with the disclosure and,therefore, are not to be considered limiting of its scope; thedisclosure will be described with additional specificity and detailthrough use of the accompanying drawings. An apparatus, system or methodaccording to some of the described embodiments can have several aspects,no single one of which necessarily is solely responsible for thedesirable attributes of the apparatus, system or method. Afterconsidering this discussion, and particularly after reading the sectionentitled “Detailed Description” one will understand how illustratedfeatures serve to explain certain principles of the present disclosure.

Embodiments described herein generally relate to systems, devices, andmethods related to gas flow control valves 100. More specifically, someembodiments relate to gas flow control valves 100 configured to finelytune the flow rate of gas extraction from solid waste landfills. Whenused herein, “flow rate” is used in reference to the volumetric flowrate passing through the flow control valve 100.

FIG. 1 illustrates a perspective view of one embodiment of a flowcontrol valve 100 coupled to a measurement tube 40 of a well head 10.Often, well heads 10 are utilized in landfills to provide a point abovethe surface to access the gas well below the surface. In one embodiment,a measurement tube 40 is connected to the well casing 20 of the wellhead 10. In some embodiments, an adapter 30 is utilized to couple themeasurement tube 40 to the well head 10. The well head 10 can provide anaccess point for technicians in the field to obtain measurementsregarding the gas within the well and to extract gas from the well. Insome embodiments, a valve can be coupled to the measurement tube 40,allowing a technician to adjust the rate of gas flowing through thevalve and thus the rate of gas extraction from the well head 10. In someembodiments, an extraction member 70 can be coupled to the valve tocapture the gases which pass through the well head 10 and the valve. Theextraction member 70 can be a flexible hose which can affixed to a pieceof pipe extending out of the flow control valve 100.

Typically, a valve will comprise a gate valve 500, such as the oneillustrated in FIG. 3A, for throttling the flow rate of gas through thewell head 10 and the valve. Gate valves 500 and similar alternatives maybe effective at limiting the flow exiting a well head 10 at high flowrates, however it can be difficult to finely tune the rate of flowexiting the well head 10 with a gate valve 500, particularly at low flowrates.

An operating goal of landfills is to remove gas at the approximate rateof its generation. Therefore, in some embodiments, the valve cancomprise a flow control valve 100 as illustrated in FIG. 1. The flowcontrol valve 100 is configured to accurately set the flow rate of gasflowing through the flow control valve 100 and exiting the well head 10,especially when the desired rate of extraction and thus the desired flowrate through the flow control valve 100 is low and/or when a preciseflow rate and/or a small adjustment to a current flow rate of a wellhead are necessary. In some embodiments, the flow control valve 100 canbe configured to throttle the flow rate in a linear fashion as the flowcontrol valve 100 is adjusted. In some embodiments, the flow controlvalve 100 can be configured to throttle flow between approximately 0 and200 cubic feet/minute (cfm). In some embodiments, the flow control valve100 can be configured to throttle flow between approximately 0 and 100cfm. In some embodiments, the flow control valve 100 can be configuredto throttle flow between approximately 0 and 50 cfm. In someembodiments, the flow control valve 100 can be configured to throttleflow between approximately 5 and 50 cfm. In some embodiments, the flowcontrol valve 100 can be configured to throttle flow betweenapproximately 5 and 40 cfm. In some embodiments, the flow control valve100 can be configured to throttle flow between approximately 20 and 40cfm. Low flow rates are considered flow rates below approximately 50 cfmor below a particular percentage of a maximum (open) flow rate, such as5%, 10%, or 20% of the maximum flow rate.

FIG. 2 illustrates a perspective view of the flow control valve 100 ofFIG. 1 coupled to the measurement tube 40. The measurement tube 40 canincorporate sensor ports 50 allowing a technician to take measurementsof the gas within the well. These measurements can include, for example,the pressure of the gas within the well head 10 or the concentrations ofconstituents in the gas, such as methane, carbon dioxide, nitrogen, andoxygen. The flow of gas can travel from the well head 10 through themeasurement tube 40 and into the proximal portion 101 of the flowcontrol valve 100 towards the distal portion 102 of the flow controlvalve 100. The flow of gas can exit the flow control valve 100 throughthe exit port 205 of the valve body 200. The flow control valve 100 canalso include a threaded member 400 and a handle 310. The measurementtube 40 can also incorporate a mating portion 60 extending outwards andconfigured to couple to a valve.

FIGS. 3A and 3B illustrates how the flow control valve 100 may be easilyretrofitted into a landfill gas system currently using other types ofvalves, such as the illustrated gate valve 500. FIG. 3A illustrates aperspective view of gate valve 500 being decoupled from a measurementtube 40. FIG. 3B illustrates a perspective view of the flow controlvalve 100 of FIG. 1 being coupled to the measurement tube 40 of FIG. 3A.In some embodiments, the flow control valve 100 can couple to themeasurement tube 40 via a union 80. In some embodiments, the union 80can be a quick disconnect fitting as illustrated in FIG. 7. Oneadvantage to the embodiments of the flow control valve 100 is that ithas the capability of mating to well heads 10 utilizing existing uniondesigns. FIGS. 3A and 3B illustrate how an existing gate valve 500 canbe decoupled from a measurement tube 40 and the flow control valve 100can quickly and easily be installed in place of the gate valve 500.

FIG. 4A illustrates a cross section view of the flow control valve 100of FIG. 1 in a closed position (e.g., no flow out of the exit port 205)and coupled to a measurement tube 40. FIG. 4B illustrates a crosssection view of the flow control valve 100 of FIG. 1 in an open position(e.g., gas flows out of the exit port 205) and coupled to a measurementtube 40. FIG. 4C illustrates a supplementary view of the cross sectionof the flow control valve 100 of FIG. 4B.

In some embodiments, the flow control valve 100 comprises a valve body200. The proximal portion of the valve body 200 can be coupled to themeasurement tube 40 via a union 80. In some embodiments, an intermediatetube 90 can be utilized to affix the valve body 200 to the union 80. Thevalve body 200 can comprise the portion of the flow control valve 100which throttles the flow rate of gas travelling through the flow controlvalve 100. In some embodiments, the valve body 200 of the flow controlvalve 100 can include a central bore 220 having a valve body 200 centralaxis. The flow control valve 100 can also include an exit port 205having an exit port 205 central axis. The exit port 205 can include anexit bore 210, the exit bore 210 being in fluid communication with thecentral bore 220 of the valve body 200.

In some embodiments, the central bore 220 of the valve body 200 has avalve body 200 central axis and the exit bore 210 of the exit port 205has an exit port 205 central axis. In some embodiments, rather thanbeing perpendicular to the valve body 200, the exit port 205 includes ashallower angle relative to the valve body 200 as illustrated in FIG.4A. In one embodiment, the exit port 205 central axis is angled between10 and 80 degrees relative to the valve body 200 central axis. Inanother embodiment, the exit port 205 central axis is angled between 20and 70 degrees relative to the valve body 200 central axis. In anotherembodiment, the exit port 205 central axis is angled between 30 and 60degrees relative to the valve body 200 central axis. In anotherembodiment, the exit port 205 central axis is angled between 40 and 50degrees relative to the valve body 200 central axis. In anotherembodiment, the exit port 205 central axis is angled approximately 45degrees relative to the valve body 200 central axis.

The shallow angle between the exit port 205 central axis and the valvebody 200 central axis may allow for smoother and/or less inhibited flowthrough the valve body 200 as compare to other valves that require thegas to turn a complete 90 degrees as would be the case if the exit port205 central axis was angled 90 degrees to the valve body 200 centralaxis. Additionally, the shallower angle may promote laminar flow,minimizing turbulence within the valve body 200, and promoting moreconsistent and accurate flow rates through the flow control valve 100,especially at low flow rates.

In some embodiments, the valve body 200 can include a valve seat 230configured to complement the valve needle 350 and accurately control theflow rate of gas travelling through the flow control valve 100, or asillustrated in FIG. 4A, inhibit the flow of gas through the flow controlvalve 100. In some embodiments, the valve seat 230 can comprise aprotrusion into the central bore 220 of the valve body 200. In someembodiments, the valve seat 230 can be integral to the valve body 200construction. In another embodiment, the valve seat 230 can be aseparate portion affixed to the valve body 200 (not illustrated). Inanother embodiment, the distal end of the intermediate tube 90 can formthe valve seat 230 (not illustrated). In one embodiment, the valve body200 incorporates a proximal socket 235 to accept the intermediate tube90. In some embodiments, the intermediate tube 90 can abut the proximalface 231 of the valve seat 230. In some embodiments, the valve seat 230can include an inner face 232. In some embodiments, the inner face 232is substantially parallel to the valve body 200 central axis. In someembodiments, the inner face 232 of the valve seat 230 can be configuredto match the inner diameter of the intermediate tube 90, ensuring smoothflow into the valve body 200 and accurate and consistent tuning of theflow rate by the flow control valve 100. In some embodiments, the innerface 232 of the valve seat 230 can be angled to complement the surfaceof the valve needle 350. In some embodiments, the valve seat 230 caninclude a distal face 233. In some embodiments, the distal face 233 ofthe valve seat 230 is configured to seal against the valve needle 350when the flow control valve 100 is in a closed position.

In some embodiments, the flow control valve 100 can also comprise athreaded member 400 having a proximal portion 401 and a distal portion402. The proximal portion 401 of the threaded member 400 can be affixedto the distal portion of the valve body 200. The threaded member 400 hasa threaded member 400 central axis. In some embodiments, the threadedmember 400 central axis is collinear with the valve body 200 centralaxis. In some embodiments, the proximal portion 401 of the threadedmember 400 can slide within the distal portion of the valve body 200. Insome embodiments, the valve body 200 and the threaded member 400 caneach include at least one retention bore 225, 406 configured to line upwith one another such that a retention member, which may include forexample, a fastener or a pin, can pass through both the valve body 200and the threaded member 400, affixing the valve body 200 to the threadedmember 400. In one embodiment, a plurality of retention bores 225, 406can be spaced evenly around the valve body 200 central axis. In someembodiments, the threaded member 400 can include a threaded bore 403 anda sliding bore 404.

In some embodiments, the flow control valve 100 can include a rotatingassembly 300 (see FIG. 5A). The rotating assembly 300 can comprise ahandle 310, a threaded shaft 330, and a valve needle 350. In someembodiments, the handle 310 is affixed to the threaded shaft 330 and thethreaded shaft 330 is affixed to the valve needle 350. The rotatingassembly 300 can be configured to rotate around the valve body 200central axis and translate along the valve body 200 central axis. Insome embodiments, the threaded bore 403 of the threaded member 400 isconfigured to accept the threaded shaft 330 of the rotating assembly 300and rotation of the rotating assembly 300 relative to the threadedmember 400 causes the rotating assembly 300 to translate relative to thethreaded member 400. In some embodiments, the valve seat 230 of thevalve body 200 is configured to receive the valve needle 350 of therotating assembly 300 such that translation of the valve needle 350relative to the valve seat 230 alters the flow rate of gas travellingthrough the flow control valve 100. In some embodiments, the exit bore210 of the exit port 205 of the valve body 200 is located distally fromthe valve seat 230 of the valve body 200 such that when the flow controlvalve 100 is in an open position and the valve needle 350 is translatedaway from the valve seat 230, as illustrated in FIG. 4B, gas can flowthrough the flow control valve 100 and out the exit port 205, but whenthe valve needle 350 is in a closed position, as illustrated in FIG. 4B,gas from the well head 10 is not allowed to flow through the flowcontrol valve 100 and out the exit port 205.

In some embodiments, the flow rate of the flow control valve 100 can beadjusted by a technician in the field. In order to increase the amountof flow, the handle 310 can be rotated in a first direction, causing therotating assembly 300, and thus the valve needle 350, to translatedistally away from the valve seat 230 of the valve body 200, increasingthe gap between the valve needle 350 and the valve seat 230. In order todecrease the amount of flow, the handle 310 can be rotated in a seconddirection. The handle 310 can also include measurement indicia 314configured to indicate the relative longitudinal position of therotating assembly 300 in relation to the threaded member 400, and thusthe valve body 200 and the valve seat 230. The longitudinal positionrefers to the displacement of the rotating assembly 300 along the valvebody 200 central axis. The measurement indicia 314 can be utilized toadjust the flow control valve 100 in order to achieve the desired flowrate. In some embodiments, the flow control valve 100 can include acorrelation between the position of the rotating assembly 300 asindicated by the measurement indicia 314 and the flow rate of the flowcontrol valve 100. In some embodiments, the measurement indicia 314 areconfigured to be read relative to the threaded member 400. In someembodiments, the measurement indicia 314 can be located on the threadedmember 400 and read relative to the location of the handle 310 (notillustrated).

In some embodiments, a technician can utilize data provided fromsensors, such as the gas pressure within the well head 10, to choose theappropriate position of the rotating assembly 300 in order to achievethe desired flow rate. In some embodiments, the pitch of the threadedbore 403 of the threaded member 400 and the threaded shaft 330 of therotating assembly 300 are configured such that each turn of the handle310 with regards to a particular pressure, produces a particular changein flow rate, allowing quick and easy adjustment of the flow controlvalve 100 in the field. In some embodiments, the pitch of the threadedbore 403 of the threaded member 400 and the threaded shaft 330 of therotating assembly 300 are configured such that several turns of thehandle 310 are required to span the adjustable range of flow rateprovided by the flow control valve 100. In some embodiments, at least 4turns of the rotating assembly 300 is required to span the adjustablerange of flow rate provided by the flow control valve 100. In someembodiments, at least 6 turns of the rotating assembly 300 is requiredto span the adjustable range of flow rate provided by the flow controlvalve 100. In some embodiments, at least 8 turns of the rotatingassembly 300 is required to span the adjustable range of flow rateprovided by the flow control valve 100. In some embodiments, at least 10turns of the rotating assembly 300 is required to span the adjustablerange of flow rate provided by the flow control valve 100. In someembodiments, at least 12 turns of the rotating assembly 300 is requiredto span the adjustable range of flow rate provided by the flow controlvalve 100. In some embodiments, at least 14 turns of the rotatingassembly 300 are required to span the adjustable range of flow rateprovided by the flow control valve 100. In some embodiments, at least 16turns of the rotating assembly 300 are required to span the adjustablerange of flow rate provided by the flow control valve 100. In someembodiments, at least 18 turns of the rotating assembly 300 are requiredto span the adjustable range of flow rate provided by the flow controlvalve 100. In some embodiments, at least 20 turns of the rotatingassembly 300 are required to span the adjustable range of flow rateprovided by the flow control valve 100. In some embodiments, at least 22turns of the rotating assembly 300 are required to span the adjustablerange of flow rate provided by the flow control valve 100. In someembodiments, at least 24 turns of the rotating assembly 300 are requiredto span the adjustable range of flow rate provided by the flow controlvalve 100. In some embodiments, at least 26 turns of the rotatingassembly 300 are required to span the adjustable range of flow rateprovided by the flow control valve 100. In some embodiments, the numberof turns necessary for the flow control valve 100 to span the adjustablerange of flow rate can depend on the particular valve needle utilized inthe flow control valve 100.

FIG. 5A illustrates a perspective view of one embodiment of a rotatingassembly 300. FIG. 5B illustrates a cross section view of the rotatingassembly 300 of FIG. 5A. In some embodiments, the proximal portion 311of the handle 310 is configured to slide within the sliding bore 404 ofthe threaded member 400. In some embodiments, the proximal portion 311of the handle 310 can include a sealing recess 313 configured to accepta sealing member. A sealing member can include for example, an O-ring.The sealing member can create a seal between the handle 310 and thethreaded member 400, ensuring the valve does not leak and produces anaccurate and consistent flow rate. In some embodiments, the handle 310is configured to be manipulated by a technician. In some embodiments,the distal portion 312 of the handle 310 can include at least onerecessed portion 316 and at least one gripping portion 315 to create asurface to grip while rotating the handle 310. In some embodiments, thehandle 310 and the threaded shaft 330 can each include at least oneretention bore 317 configured to line up with one another such that aretention member, which may include for example, a fastener or a pin,can pass through both the handle 310 and the threaded shaft 330,affixing the handle 310 to the threaded shaft 330.

In some embodiments, the valve needle 350 can include a tapered portion351. The tapered portion 351 can be a cone structure where the outsidediameter of the tapered portion 351 increases when going from theproximal end to the distal end of the tapered portion 351 of the valveneedle 350 (in the direction of gas flow). The gradual increase indiameter distally along tapered portion 351 of the valve needle 350 maypromote laminar flow, minimizing turbulence within the valve body 200,and promoting more consistent and accurate flow rates through the flowcontrol valve 100, especially at low flow rates. In some embodiments,the tapered portion 351 can be truncated such that the tapered portion351 does not come to a tip, but instead forms a proximal face 353. Insome embodiments, the proximal face 353 could be rounded or spherical inshape. In some embodiments, the tapered portion 351 can comprise atapered surface 352 much like a cone, which is flat when viewed insection as illustrated in FIG. 5B. In some embodiments, the taperedsurface 352 can be angled relative to the central axis of the rotatingassembly 300. In another embodiment, the valve needle 350 can comprise acurved profile (not illustrated). In another embodiment, the valveneedle 350 can include a parabolic shape. In some embodiments, thetapered portion 351 of the valve needle 350 can include flutes in thetapered surface 352 (not illustrated). Flutes can promote more accurateflow control at low flow rates. Thus, in some embodiments, a valveneedle with one or more flutes may be used for fine control at lowerflow rates, and a valve needle without flutes, and possibly of adifferent design, may be used for fine control at higher flow rates.

In some embodiments, the valve needle 350 can include a shoulder 354. Insome embodiments, the shoulder 354 can comprise an annular protrusionprojecting outwards from center of the valve needle 350. In someembodiments, the shoulder 354 includes a shoulder proximal face 355configured to seal with the valve seat 230 of the valve body 200 whenthe flow control valve 100 is in a closed position. In some embodiments,the shoulder 354 can include a sealing recess 356 configured to accept asealing member. The sealing member can help the shoulder 354 of thevalve needle 350 seal against the valve seat 230 of the valve body 200when the flow control valve 100 is in a closed position. In someembodiments, the sealing recess 356 can be included in the shoulderproximal face 355. In some embodiments, the valve needle 350 and thethreaded shaft 330 can each include at least one retention bore 357configured to line up with one another such that a retention member,which may include for example, a fastener or a pin, can pass throughboth the valve needle 350 and the threaded shaft 330, affixing the valveneedle 350 to the threaded shaft 330. In another embodiment, thethreaded shaft 330 may be retained longitudinally to the valve needle350, but allowed to rotate relative to the valve needle 350.

In some embodiments, the valve needle 350 can be configured to beinterchangeable. For example, the flow control valve 100 can include aplurality of valve needles that are interchangeable in order to allowthe operator to select a most appropriate valve needle to provide flowcontrol that is most appropriate for the particular flow control valve.In some embodiments, particular valve needle configurations can beconfigured to accurately throttle flow rates within a particular rangeof flow rates. In some embodiments, the flow control valve 100 caninclude a plurality of valve needles, wherein each valve needle isconfigured to accurately throttle flow rates within a particular rangeof flow rates, wherein each range is different. The flow control valve100 can include, for example, a valve needle configured to accuratelythrottle flow between approximately 5 and 20 cfm, an additional valveneedle configured to accurately throttle flow between approximately 20and 40 cfm, an additional valve needle configured to accurately throttleflow between approximately 40 and 100 cfm, and an additional valveneedle configured to accurately throttle flow between approximately 100and 200 cfm. A plurality of interchangeable valve needles allow the flowcontrol valve 100 to accurately throttle flow over a wide range of flowrates without replacing the entire flow control valve 100. In oneembodiment, a flow control valve 100 may be packaged and/or sold in akit that includes multiple valve needles having different flow rateranges at which optimal control is possible. For example, a kit may beconfigured to include any two or more of the example valve needles notedabove.

FIG. 6A illustrates a perspective view of one embodiment of a threadedmember 400. FIG. 6B illustrates a cross section view of the threadedmember 400 of FIG. 6A. In some embodiments, the proximal portion 401 ofthe threaded member 400 can include sealing recess 405 configured toaccept a sealing member. The sealing member can help the proximalportion 401 of the threaded member 400 seal against the distal portionof the valve body 200. In some embodiments, the threaded member 400 caninclude a proximal annular protrusion 407 configured to abut the distalend of the valve body 200. In some embodiments, the threaded member 400can include a distal annular protrusion 408. In some embodiments, thedistal most portion of the threaded member 400, the distal surface 409,can be a reference point from which to read the measurement indicia 314on the handle 310 of the rotating assembly 300.

In some embodiments, the threaded member 400 can include a threaded bore403. The threaded bore 403 can enter from the proximal portion 401 ofthe threaded member 400. The threaded bore 403 can be configured toaccept the threaded shaft 330 of the rotating assembly 300. In someembodiments, the threaded member 400 can include a sliding bore 404. Thesliding bore 404 can enter from the distal portion 402 of the threadedmember 400. The sliding bore 404 can be configured to accept theproximal portion 311 of the handle 310 of the rotating assembly 300. Thethreaded bore 403 can be in fluid communication with the sliding bore404.

FIG. 7 illustrates an exploded view of the union 80 of FIG. 2. In someembodiments, the union 80 can allow for quick and easy installation ofthe flow control valve 100 to a measurement tube 40. In someembodiments, the union 80 comprises a retention nut 81, a flange 82, anda quick connect 83. The flange 82 is configured to be affixed to oneportion of the system, which may include for example the mating portion60 of the measurement tube 40, and the quick connect 83 is configured tobe affixed to another portion of the system, which may include forexample the intermediate tube 90 affixed to the valve body 200 of theflow control valve 100. The retention nut 81 can include internalthreads and is configured to abut against the flange 82, and to threadonto a set of external threads located on the quick connect 83, forcingthe flange 82 and quick connect 83 together when the retention nut 81 isrotated relative to the quick connect 83. In some embodiments, theflange 82 can include a sealing recess configured to accept a sealingmember.

In some embodiments, various portions of the flow control valve 100 canbe manufactured from any suitable material or combination of materialswhich may include, for example, metals and alloys such as for example,aluminum, steel, stainless steel, titanium, iron, alloy, non-metalmaterials such as for example, polymers, carbon, ceramics and othernon-metallic materials such as plastic, thermoplastic, thermoset,acrylonitrile butadiene styrene, polycarbonate acetal, acrylic, nylon,polybutylene terephthalate, polyester liquid crystal polymer,polypropylene, polycarbonate, polyimide, polythelene, carbon fiber, orcombinations thereof. In some embodiments, portions of the flow controlvalve 100 may be manufactured from Polyvinyl chloride (“PVC”). In someembodiments, portions of the flow control valve 100 may be manufacturedfrom PVC pipe. In some embodiments, portions of the flow control valve100 can be machined form a solid piece of material or may includemachining processes completed on existing parts. In one embodiment,portions of the flow control valve 100 may be formed in an injectionmolded process. In another embodiment, portions of the flow controlvalve 100 can be formed via extrusion, casting, thermoforming,compression molding, blow molding, transfer molding, machining, threedimensional printing or any combination thereof. In one embodiment, thematerial may be reinforced with glass or carbon fibers. In someembodiments, different portions of the flow control valve 100 can beaffixed to one another using securing means which may include, forexample fasteners, clips, adhesive, cement, welding, press fits,interference fits, friction, clamps, etc.

In some embodiments, the valve body 200 can be manufactured by machiningan existing and readily available component. In one embodiment, a wyefitting, such as the socket x socket x socket schedule 80 wye fittingfrom Spears of Sylmar, Calif., can be sourced and machined to create thevalve body 200. The fitting can include a socket at each opening. In oneembodiment, a bore can be machined from the distal portion of the wyefitting producing a valve seat 230 in the proximal portion. In oneembodiment, the boring process involves extending the distal socketalmost all the way to the proximal socket 235, leaving a small amount ofmaterial which forms the valve seat 230.

In some embodiments, the flow control valve 100 can be manufactured byaffixing the distal portion of a threaded shaft 330 to a handle 310,installing the threaded shaft 330 into a threaded bore 403 of thethreaded member 400 and a proximal portion 311 of the handle 310 intothe sliding bore 404 of the threaded member 400, affixing the valveneedle 350 to the proximal portion of the threaded shaft 330, andinserting the proximal portion 401 of the threaded member 400 into thedistal end of the valve body 200 and affixing the threaded member 400 tothe valve body 200. In some embodiments, a distal portion of PVC pipe isinserted into the proximal socket 235 of the valve body 200 and affixedto the valve body 200. In some embodiments, a coupling means, which mayinclude a portion of a union 80 such as a quick connect 83, can becoupled to the PVC pipe. In some embodiments, another PCV pipe can beinserted into the exit port 205 socket 215 of the valve body 200 andaffixed to the valve body 200 and an extraction member 70, such as aflexible hose, can be coupled to the PVC pipe.

Various modifications to the implementations described in thisdisclosure may be readily apparent to those skilled in the art, and thegeneric principles defined herein may be applied to otherimplementations without departing from the spirit or scope of thisdisclosure. Thus, the claims are not intended to be limited to theimplementations shown herein, but are to be accorded the widest scopeconsistent with this disclosure, the principles and the novel featuresdisclosed herein. Additionally, a person having ordinary skill in theart will readily appreciate, the terms “upper” and “lower” are sometimesused for ease of describing the figures, and indicate relative positionscorresponding to the orientation of the figure on a properly orientedpage, and may not reflect the proper orientation of the device asimplemented.

Certain features that are described in this specification in the contextof separate implementations also can be implemented in combination in asingle implementation. Conversely, various features that are describedin the context of a single implementation also can be implemented inmultiple implementations separately or in any suitable sub combination.Moreover, although features may be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination may be directed to a subcombination or variation of a sub combination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. Further, the drawings may schematically depict one more exampleprocesses in the form of a flow diagram. However, other operations thatare not depicted can be incorporated in the example processes that areschematically illustrated. For example, one or more additionaloperations can be performed before, after, simultaneously, or betweenany of the illustrated operations. In certain circumstances,multitasking and parallel processing may be advantageous. Moreover, theseparation of various system components in the implementations describedabove should not be understood as requiring such separation in allimplementations, and it should be understood that the described programcomponents and systems can generally be integrated together in a singlesoftware product or packaged into multiple software products.Additionally, other implementations are within the scope of thefollowing claims. In some cases, the actions recited in the claims canbe performed in a different order and still achieve desirable results.

In describing the present technology, the following terminology may havebeen used: The singular forms “a,” “an,” and “the” include pluralreferents unless the context clearly dictates otherwise. Thus, forexample, reference to an item includes reference to one or more items.The term “ones” refers to one, two, or more, and generally applies tothe selection of some or all of a quantity. The term “plurality” refersto two or more of an item. The term “about” means quantities,dimensions, sizes, formulations, parameters, shapes and othercharacteristics need not be exact, but may be approximated and/or largeror smaller, as desired, reflecting acceptable tolerances, conversionfactors, rounding off, measurement error and the like and other factorsknown to those of skill in the art. The term “substantially” means thatthe recited characteristic, parameter, or value need not be achievedexactly, but that deviations or variations, including for example,tolerances, measurement error, measurement accuracy limitations andother factors known to those of skill in the art, may occur in amountsthat do not preclude the effect the characteristic was intended toprovide. Numerical data may be expressed or presented herein in a rangeformat. It is to be understood that such a range format is used merelyfor convenience and brevity and thus should be interpreted flexibly toinclude not only the numerical values explicitly recited as the limitsof the range, but also interpreted to include all of the individualnumerical values or sub-ranges encompassed within that range as if eachnumerical value and sub-range is explicitly recited. As an illustration,a numerical range of “about 1 to 5” should be interpreted to include notonly the explicitly recited values of about 1 to about 5, but alsoinclude individual values and sub-ranges within the indicated range.Thus, included in this numerical range are individual values such as 2,3 and 4 and sub-ranges such as 1-3, 2-4 and 3-5, etc. This sameprinciple applies to ranges reciting only one numerical value (e.g.,“greater than about 1”) and should apply regardless of the breadth ofthe range or the characteristics being described. A plurality of itemsmay be presented in a common list for convenience. However, these listsshould be construed as though each member of the list is individuallyidentified as a separate and unique member. Thus, no individual memberof such list should be construed as a de facto equivalent of any othermember of the same list solely based on their presentation in a commongroup without indications to the contrary. Furthermore, where the terms“and” and “or” are used in conjunction with a list of items, they are tobe interpreted broadly, in that any one or more of the listed items maybe used alone or in combination with other listed items. The term“alternatively” refers to selection of one of two or more alternatives,and is not intended to limit the selection to only those listedalternatives or to only one of the listed alternatives at a time, unlessthe context clearly indicates otherwise.

It should be noted that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the invention and withoutdiminishing its attendant advantages. For instance, various componentsmay be repositioned as desired. It is therefore intended that suchchanges and modifications be included within the scope of the invention.Moreover, not all of the features, aspects and advantages arenecessarily required to practice the present invention. Accordingly, thescope of the present invention is intended to be defined only by theclaims that follow.

1. (canceled)
 2. (canceled)
 3. (canceled)
 4. A gas flow control valvecomprising: a valve body having a central bore and an exit port, thecentral bore of the valve body having a valve body central axis, theexit port having an exit bore in fluid communication with the centralbore, the exit port of the valve body angled between about 20 and 85degrees relative to the valve body central axis; wherein the valve bodyhas a proximal portion and a distal portion, wherein gas enters thevalve body through the proximal portion and exits through the exit port;a threaded member having a proximal portion and a distal portion, theproximal portion of the threaded member affixed to the distal portion ofthe valve body, the threaded member having a threaded member centralaxis collinear with the valve body central axis, the threaded membercomprising a threaded bore and a sliding bore; and a rotating assemblyconfigured to rotate about the valve body central axis and to translatealong the valve body central axis, the rotating assembly comprising ahandle including measurement indicia configured to indicate alongitudinal position of the rotating assembly relative to the threadedmember; wherein the sliding bore of the threaded member is configured toaccept a proximal portion of the handle of the rotating assembly.
 5. Thegas flow control valve of claim 4, wherein the handle is affixed to athreaded shaft affixed to a valve needle.
 6. The gas flow control valveof claim 5, wherein the valve body includes a valve seat configured toreceive the valve needle of the rotating assembly such that translationof the valve needle relative to the valve seat alters the flow rate ofgas travelling through the gas flow control valve.
 7. The gas flowcontrol valve of claim 5, wherein the valve needle comprises a taperedportion.
 8. The gas flow control valve of claim 6, wherein the valveseat further comprises a proximal face, an inner face, and a distalface.
 9. The gas flow control valve of claim 8, wherein the distal faceof the valve seat is configured to seal against the valve needle whenthe flow control valve is in a closed position.
 10. The gas flow controlvalve of claim 8, wherein the inner face of the valve seat issubstantially parallel to a valve body central axis.
 11. The gas flowcontrol valve of claim 8, further comprising an intermediate tubeaffixing the valve body to a union.
 12. The gas flow control valve ofclaim 11, wherein the inner face of the valve seat is configured tomatch an inner diameter of the intermediate tube.
 13. The gas flowcontrol valve of claim 4, wherein the exit bore of the exit port islocated distally from the valve seat of the valve body.
 14. A valveneedle for a gas flow control valve having a valve seat, the valveneedle comprising: a tapered portion, wherein the tapered portionincreases in diameter in the direction of gas flow; and a shoulderprotruding outwards from the center of the valve needle, wherein theshoulder is configured to seal with the valve seat when the flow controlvalve is in a closed position; wherein translation of the valve needlerelative to the valve seat alters a gas the flow rate of any gasestravelling through the gas flow control valve.
 15. The valve needle ofclaim 14, wherein the shoulder further comprises a shoulder proximalface configured to seal with the valve seat when the flow control valveis in a closed position.
 16. The valve needle of claim 14, wherein theshoulder further comprises a sealing recess configured to accept asealing member.
 17. The valve needle of claim 14, wherein the taperedportion comprises a cone structure.
 18. The valve needle of claim 14,wherein the tapered portion comprises a curved profile.
 19. The valveneedle of claim 14, the tapered portion comprises a truncated shape suchthat the tapered portion forms a proximal face.
 20. The valve needle ofclaim 14, wherein the tapered portion further comprises one or moreflutes on surface of the tapered portion.
 21. The valve needle of claim14, wherein the valve needle is configured to attach to a threadedshaft.
 22. The valve needle of claim 21, wherein the threaded shaft anda threaded bore of a threaded member of the gas flow control valve havea thread pitch configured such that at least 6 turns of the threadedshaft is required to span an adjustable range of the gas flow rateprovided by the gas flow control valve.
 23. The valve needle of claim14, wherein the valve needle is configured to utilize a measurementindicia to adjust the gas flow control valve to achieve a desired flowrate.